Contoured insoles



March 3, 1970 F. FuluremzLlflY 4 3,497,892

comunas Insnns Filed June s. 1968 z sheets-sheet 1 Fyl- 1 1I InventorBenjam n 2'." lcarrellil .By his Azorne United States Patent O ice`3,497,892 CONTOURED INSOLES Benjamin F. Parrelli, Beverly, Mass.,assignor to USM Corporation, Boston, Mass., a corporation of New JerseyFiled June 3, 1968, Ser. No. 734,168

Int. Cl. A43d 3/00 U.S. Cl. 12--133 8 Claims ABSTRACT OF THE DISCLOSUREAn insole shaped insert used with a conventional last during a lastingoperation, and a method of making a shoe using such an insert. Theinsert has a surface contoured for mating engagement with the solesurface of a last and an opposite surface contoured to conform to thebottom surface of the insole to be inserted in the finished shoe.

BACKGROUND OF THE INVENTION The present invention relates to themanufacture of contoured insole shoes, and more particularly to aninsert for use in combination with a standard shaped last for use insuch manufacture, wherein the contoured insole is inserted into thepartially completed shoe after the shoe is removed from the last.

In recent years, the contoured insole shoe has met with greatacceptance, particularly in the service and dress shoe eld. Heretofore,these shoes have generally been constructed by conventional shoemakingmethods, with the contoured insole being applied to a last in lieu of anon-contoured or flat insole, and the shoe being constructed on thecontoured insole which remains as part of the shoe when removed from thelast. As may be envisioned from the foregoing description of thiscustomary manufacturing process, a last having modified structure fromthat of a standard last is necessary to accommodate the contour surfaceof the `insole during shoe construction. For a manufacturer to get intothe contour insole eld therebefore, it is necessary iirst to obtainlasts of modified construction, to accommodate this shoe construction.

With the increase in popularity of the contour insole shoe, manymanufacturers have been forced into purchas ing a complete set of laststo accommodate these shoes, the lasts being of such modified structurethat they are capable of only accommodating shoes built on a contouredinsole. Thus, the investment in new lasts to enter the contour insolefield involves somewhat of a risk in that a possibility exists that thelasts will only be subjected to limited use during normal plantoperation by a manufacturer, and the entire line of lasts may be madeobsolete should the popularity of the contour insole wane.

A primary object of the invention therefore, is to allow a shoemanufacturer to proceed conventionally in the manufacture of contouredinsole shoes without the problems and hazards connected with speciallasting, welt rib attaching, heel seat treatment, etc., which areinvolved when contour insoles are built in as part of the lasted shoe.

A second object of the invention is to enable a shoe manufacturer toproduce shoes having a contoured insole by employing a standard lastused in the manufacture of non-contoured insole shoes.

Another object of the invention is to provide an article which is usedin combination with a standard shaped last in the manufacture ofcontoured insole shoes.

A further object of the present invention is to provide a method ofmanufacturing contoured insole shoes wherein a standard last is used toconstruct the shoe.

3,497,892 Patented Mar. 3, 1970A A more general object of the presentinvention is to facilitate the manufacture of contour insole shoes without the large investment in lasts which have heretofore been necessary,by enabling the manufacturer to temporarily modify a standard last formanufacturing contoured insole shoes, after which the last may be againused for standard shoe construction.

SUMMARY OF THE INVENTION To achieve the objects of the persentinvention, as set forth, an article of manufacture is provided havingits one surface conforming generally to the sole surface of a standardlast, and its opposite surface conforming generally to the sole surfaceof a contoured insole to be used in the shoe construction. The articlegenerally comprises a forepart and a back part hingedly connected one tothe other. The hinged construction permits the use of the article with astandard two-part last having a forward portion and a heel portion whichare opened to facilitate removal of the shoe from the last.

In the method aspect, the forepart of the article is generally attachedin a temporary manner such as by tacks, staples, etc., to the forwardportion of the last and the back part of the article is rested, withoutfastening, on the heel portion of the last. A shoe of standardconstruction, with exception of the insole, is now constructed on thelast and article combination. When the construction is complete, thelast is opened and the shoe removed, after which a contoured insole isinserted in the shoe.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. l is a plan view of an article ofmanufacture for use in combination with a standard last, and constructedin accordance with the teachings of the present invention;

FIG. 2 is a sectional view taken along the line II-II of FIG. l showingdetails of the article taken on an enlarged scale for clarity;

FIG. 3 is an elevational view, partially in section, showing the articleattached to a Standard last;

FIG. 4 is a sectional elevational view similar to FIG. 3, showing a shoeconstruction manufactured on the last structure shown in FIG. 3, justprior to removal from the last;

FIG. 5 is an elevational view similar to FIG. 4, showing the last andarticle combination in its open position during removal of the shoestructure therefrom;

FIG. 6 is a sectional elevational view of a contoured insole to be usedin the shoe structure of FIGS. 4 and 5, showing the article of FIGS. 1and 2 superimposed thereon in phantom lines; and

FIG. 7 is a sectional view taken along the line VII--VII of FIG. 6showing details of the contoured insole and superimposed articlestructure, taken on an enlarged scale for clarity.

' DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings,in particular FIGS. 1 and 2, there is shown an article of manufacture inthe form of a last insert 10 which is constructed to be used incombination with a standard shaped last in the manufacture of contouredinsole shoes. The insert 10, shown in plan form in FIG. 1, is of a shapeand size to substantially cover the sole portion of the standard lastand generally comprises a forepart 11 and a back part 12. The insert 10is so formed as to have a surface 13 conforming generally to the solesurface of a standard last with which the insert is to be used. Theopposite surface 14 is fabricated to conform to the shape of the solesurface of a contoured insole which is to be inserted into a shoeconstructed on, and after its removal from, the last. The insert 10 maybe fabricated from any known material which will readily receivefasteners such that a shoe may be manufactured in the standard manner asby tacking a thin sheet of insole material to the insert and the last.

However, it has been found advantageous to manufacture the last insertfrom a moldable plastic material such as a polyurethane. By providing amold hav- -ing the proper contours desired in the insert construction,

an inexpensive and semi-rigid structure is produced having the roundedsurface contours necessary to conform both to the last sole surface, andthe contour insole sole surface. Further, as it is necessary tomanufacture an insert 10` for each size of standard last, the use ofmoldable plastic as an insert material can create a substantial savingsin cost over an entire run of insert sizes. A set of molds is thusprovided, each corresponding to a different insert size, each of whichmay be used to produce any given number of inserts 10 which areidentical in contour and size, to mate with the appropriate last size.

In the process of forming the insert 10, the mold may be constructed toprovide a recessed area onto which a heel plate is fastened. The heelplate 15 serves to take the place of the last heel plate which iscovered by the insert 1t)` during the shoe construction, as will becomeevident in the description which follows.

Referring still to FIGS. l and 2 it will be noted that the forepart 11and the back part 12 are connected by a hinge 16. While the hinge 16 maytake any form which is convenient in fastening the forepart 11 and theback part 12 together, in the insert 10 as shown, the hinge is formed bymolding a sheet of canvas cloh, polystyrene plastic, or other flexiblematerial into the insert when it is formed. Thus, the manufacture of theinsert as a molded plastic member has the added advantage in that thehinge 16 may be molded into the forepart 11 and the back part 12 to forma unitary structure without the undesirable distortion of the surfaces13 and 14, resulting from fastening the members together by othermethods.

Referring to FIG. 3, there is shown a standard last 17 having a forwardportion 18 and a heel portion 19 movable about a hinge point 21 from theclosed position (as shown in FIG. 3) to an open position, for removal ofthe shoe structure therefrom. With the last 17 in the closed position asshown, a sole surface 22 is presented on which the insert 10 is placedin mating engagement, the insert surface 13 having been contoured tocorrespond to the last sole surface 22 as explained heretofore. Theforefart of the insert 10 is now attached to the forward portion 18 ofthe last 17 -by tacks 23, or other suitable fasteners. It will be notedthat only the forepart 11 of the insert 10 is attached to the last 17,the back part 12 merely resting on the last. As will be observed in FIG.3, the hinge line between the forepart 11 and the back part 12 islocated approximately at the separation line between the forward portion18 and the heel portion 19 of the last 17.

With the insert 10 so attached to the last 17, a shoe is constructed onthe combination such as is shown in FIGS. 4 and 5. The shoe may be ofany well known construction such as a Goodyear welt, cement, lockstitchor any such construction as is well known in the art.

In FIGS. 4 and 5 there is shown a shoe construction 24 built byfastening the component parts upon a thin piece of insole material 26which is rst tacked or otherwise temporarily fastened to the insert 10in the initial construction of the shoe. The upper 27, outsole 28 andheel 29 are all assembled into the shoe 24 in the usual manner as wouldbe accomplished were the shoe being built upon the last 17 without theinsert 10 applied thereto.

Referring now to FIG. 5, with the shoe constructed on the last 17 in theusual manner, the last 17 is opened to provide release of the shoe 24from the last, the heel end of the shoe being lifted from the heelportion 19 as shown in that figure. It will further be observed in that.4 ligure that the back part 12 of the insert 10 is now free to moverelative to the heel portion 19 of the last 17, and folds down upon theheel portion 19 of the last to provide for removal of the shoe 214 fromthe last 17 in the usual manner. As will be noted in FIG. 5, both theforepart 11 and the back part 12 of the insert 10 are chamfered adjacentthe hinge 16 so that a wide range of movement is provided for betweenthe two insert parts.

With the removal of the shoe 24 from the last 18, the insert 10 remainson the last, and another run of contour insole shoes may be madeemploying the last and insert combination. However, should it be desiredto change over to a run of non-contoured insole shoes, the insert 10 iseasily removed from the last 18, and, because of its size, requires arelatively small storage space to accommodate it until it is againapplied to the last, as hereinbefore described. As will now be noted,the shoe structure 24 is similar in all respects to a shoe manufacturedon the standard last 17 without the insert 10, but for a space providedat the sole of the shoe, and a contour in the insole portion of the shoewhich has been constructed to receive a contoured shaped insole.

The shoe '24 as now constructed, is provided with an inner sole surfacecontour 31 which substantially conforms to the surface 14 of the lastinsert.

In FIGS. 6 and 7 there is shown a contoured insole 33 having a contoursurface 34 shaped to conform to the wearers foot and a sole surface 36.superimposed on the insole 33, as shown in the phantom lines of FIG. 7,is the last insert 10. As should be evident from these figures, the solesurface 36 of the insole 33 and the sole surface of the insert 10 areidentical, while the conforming surface 13 of the insert 10 variessubstatially from the contoured surface 34 of the contour insole. Thedifference in contour between the surface 34 of the insole 33 and thesurface 13 of the insert 10 is generally that portion of the standardlast which is removed to provide a last on which contoured insole shoesmay be fabricated, in prior art shoe construction.

Thus, the thickness dimension of the insert 10 is dictated by thethickness of the insole 33 to be placed in the shoe after removal fromthe last. The thickness dimension of the insert is such that a shoemanufactured by employing the insert, and having the contoured insolesubsequently inserted therein, provides the wearer the proper shoe sizecorresponding to the standard last size on which the shoe was made.

From the foregoing therefore, it will be appreciated that the variousobjects of the present invention are accomplished by providing theinsert 10 which when used with a standard last to manufacture contouredinsole shoes enables a shoe manufacturer to produce contoured insoleshoes with a minimum of investment. Additionally, the manufacturer mayquickly and easily convert to contoured insole shoe manufacture and backto manufacture of non-contoured insole shoes should the need arise to doso.

While the invention has been shown in but one form, it will be obviousto those skilled in the art that it is not so limited, but issusceptible of various changes and modications without departng from thespirit thereof.

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent of the United States is:

1. An article for use in combination with a last having a standardshaped sole surface in the manufacture of shoes wherein an insole isinserted after the shoe is removed from the last, said article having asurface contoured for mating engagement with the sole suface of thestandard last and an opposite surface contoured to conform to the bottomsurface of the insole to be inserted in the finished shoe when removedfrom the last.

2. An article in accordance with claim 1 which is fabricated from amoldable plastic material.

3. An article in accordance with claim 2 wherein said material is apolyurethane plastic.

4. An article for use in combination with a last having a forwardportion and a heel portion forming a standard shaped sole surface saidportions being movable between an open and a closed position, comprisinga forepart and a back part, said forepart having a surface contoured formating engagement with the sole surface of the last forward portion andsaid back part having a surface contoured for mating engagement with thesole surface of the last heel portion, the opposite surface of saidforepart and the opposite surface of said back part being contoured toconform to the bottom surface of an insole to be inserted in thefinished shoe when removed from the last.

5. A method of manufacturing a shoe having a contoured insole on a lasthaving a standard shaped sole surface which comprises the steps ofproviding an insert member having a rst surface contoured for matingengagement with the sole surface of the last and a second surfacecontoured in accordance with the bottom surface of an insole to beinserted in the shoe when removed from the last, attaching the insert tothe last with said first contoured surface engaging the sole surface ofthe last, assembling components including an upper and an outsole onsaid last to form a partially completed shoe Structure, removing saidpartially completed shoe structure from said last and inserting acontoured insole in the shoe structure.

6. A method of manufacturing a shoe having a contoured insole on a lastcomprising a forward portion and a heel portion forming a standardshaped sole surface and movable between an open and a closed position,which comprises the steps of providing an insert member having aforepart and a back part hingedly connected for relative movement one tothe other and a surface contoured for mating engagement with the lastsole,

attaching one of said insert parts only to the Sole surface of the last,

assembling components including an upper and an outsole on said last toform a partially completed shoe structure,

removing Said partially completed shoe structure from the last byopening the last with the insert attached thereto and inserting acontoured insole in the shoe structure.

7. An article for use in combination with a last having a forwardportion and a heel portion forming a standard shaped sole surface, saidportions being movable between an open and a closed position, comprisinga forepart and a back part hingedly connected for relative movement oneto the other, said forepart having a surface contoured for matingengagement with the sole surface of the last forward portion and saidback part having a surface contoured for mating engagement with the solesurface of the last heel portion, the opposite surface of said forepartand the opposite surface of said back part being contoured to conform tothe bottom surface of an insole to be inserted in the finished shoe whenremoved from the last.

8. An article in accordance with claim 7 which further includes a heelplate disposed on said opposite surface of said back part.

References Cited UNITED STATES PATENTS 1,120,490 12/1914 Hilgert 12-1332,138,974 12/ 1938 MacDonald 12--146 X 3,181,186 5/1965 Hunt 12-1363,266,178 8/ 1966 Gilkerson 36-43 PATRICK D. LAWSON, Primary ExaminerU.S. Cl. X.R. 12--146

